ignition DODGE RAM 2002 Service Repair Manual

(d) Tighten sensor to 2±3 N´m (15±20 in. lbs.)
torque.
(e) Connect electrical connector to WIF sensor.
(f) Install fuel filter. Refer to previous steps.
(4)Fuel Heater Element:
(a) Do not install fuel filter until heater element
is installed.
(b) Position heater element into filter housing
(fingers downward). Lock fingers into housing.
(c) Install new o-ring to electrical connector
(where connector passes through filter housing).
Apply a light film of clean diesel oil to o-ring seal.
Press this connector into filter housing until it
snaps into heater element.
(d) Install temperature sensor housing and 2
mounting screws to fuel filter housing.
(e) Connect electrical connector.
(f) Install fuel filter. Refer to previous steps.
(5)Drain Valve:
(a) Install 2 new o-rings to valve and filter hous-
ing.
(b) Apply a light film of clean diesel oil to both
seals.
(c) Position valve to filter housing.
(d) Install 4 mounting screws and tighten to 3±5
N´m (30±40 in. lbs.) torque.
(e) Connect drain hose to drain valve.
(f) Install fuel filter. Refer to previous steps.
(6) Start engine and check for leaks.
FUEL HEATER
DESCRIPTION
The fuel heater assembly is located on the side of
the fuel filter housing (Fig. 18).
The heater/element assembly is equipped with a
temperature sensor (thermostat) that senses fuel
temperature. This sensor is attached to the fuel heat-
er/element assembly.
OPERATION
The fuel heater is used to prevent diesel fuel from
waxing during cold weather operation.
When the temperature is below 45  8 degrees F,
the temperature sensor allows current to flow to the
heater element warming the fuel. When the temper-
ature is above 75  8 degrees F, the sensor stops cur-
rent flow to the heater element.
Battery voltage to operate the fuel heater element
is supplied from the ignition switch and through the
fuel heater relay. Also refer to Fuel Heater Relay.
The fuel heater element and fuel heater relay
are not computer controlled.
The heater element operates on 12 volts, 300 watts
at 0 degrees F.
DIAGNOSIS AND TESTING - FUEL HEATER
The fuel heater is used to prevent diesel fuel from
waxing during cold weather operation.
NOTE: The fuel heater element, fuel heater relay
and fuel heater temperature sensor are not con-
trolled by the Powertrain Control Module (PCM).
A malfunctioning fuel heater can cause a wax
build-up in the fuel filter/water separator. Wax
build-up in the filter/separator can cause engine
starting problems and prevent the engine from rev-
ving up. It can also cause blue or white fog-like
exhaust. If the heater is not operating in cold tem-
peratures, the engine may not operate due to fuel
waxing.
The fuel heater assembly is located on the side of
the fuel filter housing (Fig. 19).
The heater assembly is equipped with a built-in
fuel temperature sensor (thermostat) that senses fuel
temperature. When fuel temperature drops below 45
degrees   8 degrees F, the sensor allows current to
flow to the built-in heater element to warm the fuel.
When fuel temperature rises above 75 degrees   8
degrees F, the sensor stops current flow to the heater
element (circuit is open).
Fig. 18 Fuel Heater Location
1 - FUEL HEATER AND TEMP. SENSOR
2 - FUEL FILTER/WATER SEPARATOR
3 - FUEL HEATER ELECTRICAL CONNECTOR
14 - 66 FUEL DELIVERY - DIESELBR/BE
FUEL FILTER / WATER SEPARATOR (Continued)

Voltage to operate the fuel heater element is sup-
plied from the ignition switch, through the fuel
heater relay (also refer to Fuel Heater Relay), to the
fuel temperature sensor and on to the fuel heater ele-
ment.
The heater element operates on 12 volts, 300 watts
at 0 degrees F. As temperature increases, power
requirements decrease.
A minimum of 7 volts is required to operate the
fuel heater. The resistance value of the heater ele-
ment is less than 1 ohm (cold) and up to 1000 ohms
warm.
TESTING
(1) Disconnect electrical connector at sensor (Fig.
19).
Turn key to ON position. 12 volts should be
present at red wire. If not, check fuel heater relay
and related wiring. Refer to Relay TestÐFuel Heater.
If OK, proceed.
Turn key OFF. Check black wire in connector for
ground continuity with an ohmmeter. If continuity is
not present, correct open ground circuit. This test can
also be performed with a voltmeter by backprobing
black wire with it connected to sensor. Reconnect elec-
trical connector and turn key ON. Voltage drop should
not exceed 2 volts (2 volts lower than checked at 12V+
connector). If voltage is lower, check for dirty or cor-
roded ground connection and repair. If OK, proceed.
(2) With electrical connector disconnected at sen-
sor and key OFF, check electrical/mechanical opera-
tion of fuel temperature sensor. Proceed to next step:
(3) Using an ohmmeter, check for continuity across
two terminals in electrical connector at side of sen-
sor. Sensor circuit should be open if fuel temperature
has risen above 75 degrees   8 degrees F. Sensor cir-
cuit should be closed if fuel temperature has dropped
below 45 degrees   8 degrees F. If not, replace fuel
heater assembly. This same test can also be per-
formed using a voltmeter, with key ON, and by back-
probing connector.
REMOVAL/INSTALLATION
The fuel heater/element/sensor assembly is located
inside of the fuel filter housing. Refer to Fuel Filter/
Water Separator Removal/Installation for procedures.
FUEL HEATER RELAY
DESCRIPTION
The fuel heater relay is located in Power Distribu-
tion Center (PDC) (Fig. 20). Refer to label on inside
of PDC cover for relay location.
OPERATION
Battery voltage to operate the fuel heater element
is supplied from the ignition switch through the fuel
heater relay.The fuel heater element and fuel
heater relay are not computer controlled.
Fig. 19 Fuel Heater Location
1 - FUEL HEATER AND TEMP. SENSOR
2 - FUEL FILTER/WATER SEPARATOR
3 - FUEL HEATER ELECTRICAL CONNECTOR
Fig. 20 Power Distribution Center Location
1 - CLIP
2 - BATTERY
3 - TRAY
4 - NEGATIVE CABLE
5 - POSITIVE CABLE
6 - CLIP
7 - FENDER INNER SHIELD
8 - POWER DISTRIBUTION CENTER
BR/BEFUEL DELIVERY - DIESEL 14 - 67
FUEL HEATER (Continued)

WATER IN FUEL SENSOR
DESCRIPTION
The WIF sensor is located on the side of the fuel
filter/water separator canister (Fig. 68).
OPERATION
The sensor sends an input to the Engine Control
Module (ECM) when it senses water in the fuel filter/
water separator. As the water level in the filter/sep-
arator increases, the resistance across the WIF
sensor decreases. This decrease in resistance is sent
as a signal to the ECM and compared to a high
water standard value. Once the value reaches 30 to
40 kilohms, the ECM will activate the water-in-fuel
warning lamp through CCD bus circuits. This all
takes place when the ignition key is initially put in
the ON position. The ECM continues to monitor the
input at the end of the intake manifold air heater
post-heat cycle.
REMOVAL
The Water-In-Fuel (WIF) sensor is located at the
side of fuel filter/water separator canister. Refer to
Fuel Filter/Water Separator Removal/Installation for
WIF sensor removal/installation procedures.
FUEL DRAIN MANIFOLD
DESCRIPTION
The fuel drain manifold is actually a rifled passage
within the cylinder head (Fig. 69).
OPERATION
When the engine is running, and during injection,
a small amount of fuel flows past the injector nozzle
and is not injected into the combustion chamber. This
fuel is used to lubricate the fuel injectors. Excess fuel
drains into the fuel drain manifold (or passage). Fuel
is drained from this passage into a line at the rear of
the cylinder head (Fig. 69). After exiting the cylinder
head, fuel is routed (returned) back to the fuel tank.
A ªTº is installed into the fuel return line (Fig. 69).
This ªTº is used to allow excess fuel from the injec-
tion pump to be returned into the fuel tank. A one-
way check valve within the overflow valve prevents
fuel (from the fuel drain manifold) from entering the
fuel injection pump.
Asmallamount of fuel is returned from the fuel
injectors, while alargeamount (about 70% of sup-
plied fuel) is returned from the fuel injection pump.
Fig. 68 Water-in-Fuel Sensor Location
1 - WATER-IN-FUEL (WIF) SENSOR
2 - FUEL FILTER/WATER SEPARATOR
3 - WIF SENSOR CONNECTOR
Fig. 69 Fuel Drain Manifold Passage
1 - REAR OF CYLINDER HEAD
2 - BANJO FITTING/BOLT
3 - FUEL RETURN TO TANK
4 - FUEL RETURN LINES
5 - FUEL RETURN LINE FROM PUMP OVERFLOW VALVE
6 - FUEL DRAIN MANIFOLD PASSAGE
7 - ªTº
BR/BEFUEL DELIVERY - DIESEL 14 - 89

COLUMN
TABLE OF CONTENTS
page page
COLUMN
DESCRIPTION..........................6
OPERATION
SERVICE PRECAUTIONS................6
REMOVAL.............................6
INSTALLATION..........................8
SPECIFICATIONS
TORQUE CHART......................9
KEY-IN IGNITION SWITCH
DESCRIPTION..........................9
DIAGNOSIS AND TESTING - IGNITION
SWITCH AND KEY LOCK CYLINDER.......9
LOCK CYLINDER
REMOVAL.............................10INSTALLATION.........................10
IGNITION SWITCH
DESCRIPTION.........................11
OPERATION...........................11
DIAGNOSIS AND TESTING - IGNITION
SWITCH.............................11
REMOVAL.............................12
INSTALLATION.........................12
GEAR SHIFT LEVER
REMOVAL.............................14
INSTALLATION.........................15
STEERING WHEEL
REMOVAL.............................15
INSTALLATION.........................15
COLUMN
DESCRIPTION
The tilt and standard column (Fig. 1) has been
designed to be serviced as an assembly; less wiring,
switches, shrouds, steering wheel, etc. Most steering
column components can be serviced without remov-
ing the steering column from the vehicle.
OPERATION
SERVICE PRECAUTIONS
Safety goggles should be worn at all times when
working on steering columns.
To service the steering wheel, switches or the air-
bag, refer to the WARNINGS and CAUTIONS below.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIRBAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE. FAILURE TO DO SO COULD RESULT IN
ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND
POSSIBLE PERSONAL INJURY. THE FASTENERS,
SCREWS, AND BOLTS, ORIGINALLY USED FOR
THE AIRBAG COMPONENTS, HAVE SPECIAL COAT-INGS AND ARE SPECIFICALLY DESIGNED FOR THE
AIRBAG SYSTEM. THEY MUST NEVER BE
REPLACED WITH ANY SUBSTITUTES. ANYTIME A
NEW FASTENER IS NEEDED, REPLACE WITH THE
CORRECT FASTENERS PROVIDED IN THE SERVICE
PACKAGE OR FASTENERS LISTED IN THE PARTS
BOOKS.
CAUTION: Do not hammer on steering column shaft
or shift tube. This may cause the shaft/shift tube to
collapse or damage the bearing.
CAUTION: Do not attempt to remove the pivot pins
to disassemble the tilting mechanism. Do not
remove shaft lock plate, plate retainer, park lock
link or slider. This will damage the column (Fig. 2)
and (Fig. 3).
REMOVAL
(1) Position the front wheels straight ahead.
(2) Disconnect the negative (ground) cable from
the battery.
(3) Remove the airbag, (Refer to 8 - ELECTRICAL/
RESTRAINTS/DRIVER AIRBAG - REMOVAL).
(4) Remove the steering wheel with an appropriate
puller,(Refer to 19 - STEERING/COLUMN/STEER-
ING WHEEL - REMOVAL).
19 - 6 COLUMNBR/BE

CAUTION: Ensure the puller bolts are fully engaged
into the steering wheel and not into the clock-
spring, before attempting to remove the wheel. Fail-
ure to do so may damage the steering wheel.
(5) Remove the shift link rod in the engine com-
partment (if equipped). Pry the rod out from the
grommet in the shift lever.
(6) Scribe or paint reference mark on the column
shaft-to-coupler. This will aid in column shaft instal-
lation alignment. Remove the steering column shaft-
to-coupler bolt (Fig. 4).
(7) Remove the steering column opening cover/
knee blocker, (Refer to 23 - BODY/INSTRUMENT
PANEL/STEERING COLUMN OPENING COVER -
REMOVAL).
Fig. 1 Steering Column
1 - STEERING WHEEL
2 - TILT LEVER
3 - UPPER SHROUD
4 - PANEL BRACKET
5 - SPACER
6 - TOE PLATE
7 - NUT
8 - LOWER SHROUD
9 - CLOCK SPRING
10 - NUT
Fig. 2 Observe Cautions
1 - CAUTION: NEVER REMOVE IGNITION LOCKING LINK
2 - CAUTION: NEVER REMOVE PARK LOCK SLIDER
3 - CAUTION: NEVER REMOVE SHAFT LOCK PLATE
Fig. 3 Observe Cautions
1 - CAUTION: NEVER REMOVE SHAFT LOCK PLATE RETAINER
Fig. 4 Steering Coupler-Typical
1 - STEERING COUPLER
2 - STEERING COLUMN
3 - SHIFT LEVER
BR/BECOLUMN 19 - 7
COLUMN (Continued)

(8) Remove the PRNDL cable on column shift vehi-
cles. Put the shift lever inParkposition. Pull the
cable and twist to remove from the position arm.
Push the tab up on bottom of the cable retainer, then
squeeze sides to remove retainer from the column
(Fig. 5).
(9) Remove the tilt lever (if equipped) from the col-
umn.
(10) Remove the upper and lower lock housing
shroud and remove the lower fixed shroud.
(11) Remove the turn signal multi-function switch
connector with a 7mm socket (Fig. 6).(12) Loosen the upper Support Bracket nuts to
allow some slack. This will aid in removal of the
upper fixed shroud.
(13) Remove the electrical connections from Key-in
light, Ignition Switch, Horn, Overdrive Switch and
Clock Spring (Speed Control) (Fig. 7).
(14) Remove the wiring harness from the column
by prying out the plastic retainer buttons.
(15) Remove the toe plate fasteners.
(16) Remove the column from vehicle.
(17) Remove the Ignition and Multi-Function
Switch, then remove the Clock Spring and tape the
Clock Spring to prevent it from turning, (Refer to 8 -
ELECTRICAL/RESTRAINTS/CLOCKSPRING -
REMOVAL).
INSTALLATION
(1) Install the clock spring and switches, (Refer to
8 - ELECTRICAL/RESTRAINTS/CLOCKSPRING -
INSTALLATION).
NOTE: Turn the Ignition Switch to the on position
and verify the gear shifter moves. If the shifter does
not move ensure the Ignition Switch is installed
properly.
(2) Column shift vehicles, install a new grommet.
Use multi-purpose lubricant, or equivalent, to aid
installation of the grommet.
NOTE: A new grommet should be used when ever
the rod is disconnected from the lever.
Fig. 5 PRNDL Drive
1 - PRNDL LEVER
2 - THUMB SCREW
3 - CABLE RETAINER
4 - PRNDL CABLE
Fig. 6 Multi-function Switch
1 - STEERING COLUMN ASSY.
2 - MULTI-FUNCTION SWITCH CONNECTOR
3 - TURN SIGNAL SWITCH AND LEVER
Fig. 7 Steering Column Wiring
1 - KEY-IN SWITCH & HALO LIGHT
2 - MULTI-FUNCTION SWITCH
3 - TURN SIGNAL SWITCH & LEVER
4 - IGNITION SWITCH
5 - SPEED CONTROL
19 - 8 COLUMNBR/BE
COLUMN (Continued)

(3) Remove the shipping lock pin if necessary.
(4) Install the column through the floor pan.
(5) Position the column bracket breakaway cap-
sules on the mounting studs. Install, butloose
assemblethe two upper bracket nuts.
(6) With the front wheels in the straight-ahead
position. Align steering column shaft to the coupler.
Install anewpinch bolt and tighten to 49 N´m (36
ft. lbs.).
(7) Clip the wiring harness on the steering column.
Connect the multi- function switch wiring and
tighten with 7mm socket.
(8) Install the upper fixed shroud.
(9) Be sure both breakaway capsules are fully
seated in the slots in the column support bracket.
Pull the column rearward then tighten upper bracket
nuts to 12 N´m (105 in. lbs.).
(10) Tighten the toe plate to floor pan attaching
nuts to 22.5 N´m (200 in. lbs.).
(11) Install the wiring connections to the column.
Install the lower fixed shroud.
(12) Column shift vehicles, install the PRNDL
driver cable. Place shifter in Park position. If indica-tor needs adjusting, turn thumb screw on cable
retainer to adjust cable.
(13) Install the lock housing shrouds. Install the
tilt lever (if equipped).
(14) Install the knee blocker and steering column
opening cover, (Refer to 23 - BODY/INSTRUMENT
PANEL/STEERING COLUMN OPENING COVER -
INSTALLATION).
(15) Install steering wheel and tighten nut to 61
N´m (45 ft. lbs.), (Refer to 19 - STEERING/COL-
UMN/STEERING WHEEL - INSTALLATION).
(16) Install the airbag, (Refer to 8 - ELECTRICAL/
RESTRAINTS/DRIVER AIRBAG - INSTALLATION).
(17) Column shift vehicles, connect the shift link
rod to the transmission shift lever. Use multi-purpose
lubricant, or an equivalent product, to aid the instal-
lation.
(18) Install the battery ground (negative) cable.
(19) Verify operation of the automatic transmission
shift linkage and adjust as necessary, (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC -
44RE/GEAR SHIFT CABLE - ADJUSTMENTS).
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Steering Wheel
Nut61 45 Ð
Steering Coupler
Bolt49 36 Ð
Steering Column
Upper Bracket12 Ð 105
Steering Column
Toe Plate23 Ð 200
KEY-IN IGNITION SWITCH
DESCRIPTION
The key-in ignition switch is integral to the igni-
tion switch, which is mounted on the left side of the
steering column. It closes a path to ground for the
Central Timer Module (CTM) when the ignition key
is inserted in the ignition lock cylinder and the
driver door ajar switch is closed (driver door is open).
The key-in ignition switch opens the ground path
when the key is removed from the ignition lock cyl-
inder. The ground path is also opened when the
driver door ajar switch is open (driver door is closed).The key-in ignition switch cannot be repaired and,
if faulty or damaged, the entire ignition switch must
be replaced, (Refer to 19 - STEERING/COLUMN/IG-
NITION SWITCH - REMOVAL).
DIAGNOSIS AND TESTING - IGNITION SWITCH
AND KEY LOCK CYLINDER
ELECTRICAL DIAGNOSIS
For ignition switch electrical schematics, refer to
Ignition Switch in the appropriate section of Electri-
cal Wiring Diagrams.
BR/BECOLUMN 19 - 9
COLUMN (Continued)

MECHANICAL DIAGNOSIS (KEY DIFFICULT TO
ROTATE)
Vehicles equipped with an automatic trans-
mission and a floor mounted shifter:a cable is
used to connect the interlock device in the steering
column assembly, to the transmission floor shift
lever. This interlock device is used to lock the trans-
mission shifter in the PARK position when the key
lock cylinder is rotated to the LOCKED or ACCES-
SORY position. The interlock device within the steer-
ing column is not serviceable. If repair is necessary,
the steering column assembly must be replaced.
(Refer to 19 - STEERING/COLUMN - REMOVAL).
If the ignition key is difficult to rotate to or from
the LOCK or ACCESSORY position, it may not be
the fault of the key cylinder or the steering column
components. The brake transmission shift interlock
cable may be out of adjustment. Refer to Brake
Transmission Shift Interlock Cable Adjustment in
Transmissions for adjustment procedures.
Vehicles equipped with an automatic trans-
mission and a steering column mounted shifter:
an interlock device is located within the steering col-
umn. This interlock device is used to lock the trans-
mission shifter in the PARK position when the key
lock cylinder is in the LOCKED or ACCESSORY
position. If it is difficult to rotate the key to or from
the LOCK or ACCESSORY position, the interlock
device within the steering column may be defective.
This device is not serviceable. If repair is necessary,
the steering column assembly must be replaced.
(Refer to 19 - STEERING/COLUMN - REMOVAL).
Vehicles equipped with a manual transmis-
sion and a floor mounted shifter:on certain mod-
els, a lever is located on the steering column behind
the ignition key lock cylinder. The lever must be
manually operated to allow rotation of the ignition
key lock cylinder to the LOCK or ACCESSORY posi-
tion. If it is difficult to rotate the key to the LOCK or
ACCESSORY position, the lever mechanism may be
defective. This mechanism is not serviceable. If
repair is necessary, the steering column assembly
must be replaced. (Refer to 19 - STEERING/COL-
UMN - REMOVAL).
On other models, the ignition key cylinder must be
depressed to allow it to be rotated into the LOCK or
ACCESSORY position. If it is difficult to rotate the
key to the LOCK or ACCESSORY position, the lock
mechanism within the steering column may be defec-
tive. This mechanism is not serviceable. If repair is
necessary, the steering column assembly must be
replaced. (Refer to 19 - STEERING/COLUMN -
REMOVAL).
LOCK CYLINDER
REMOVAL
The ignition key must be in the key cylinder for
cylinder removal.
(1) Disconnect negative cable from battery.
(2) If equipped with tilt column, remove tilt lever
by turning it counterclockwise.
(3) Remove upper and lower covers (shrouds) from
steering column (Fig. 8).
(4) If equipped with automatic transmission, place
shifter in PARK position.
(5) A retaining pin (Fig. 9) is located at side of key
cylinder assembly.
(a) Rotate key to RUN position.
(b) Press in on retaining pin while pulling key
cylinder from ignition switch.
INSTALLATION
The ignition key must be in the key cylinder and
turned clockwise to the RUN position for cylinder
installation.
Fig. 8 Shroud Removal/InstallationÐTypical
1 - NUT
2 - STEERING WHEEL
3 - TILT LEVER
4 - UPPER SHROUD
5 - PANEL BRACKET
6 - SPACER
7 - NUT
8 - LOWER SHROUD
9 - CLOCK SPRING
19 - 10 COLUMNBR/BE
KEY-IN IGNITION SWITCH (Continued)

(1) Install the lock cylinder into the housing using
care to align the end of the lock cylinder with the
ignition switch.
(2) Push the lock cylinder in until it clicks.
IGNITION SWITCH
DESCRIPTION
The electrical ignition switch is located on the
steering column. It is used as the main on/off switch-
ing device for most electrical components. The
mechanical key lock cylinder is used to engage/disen-
gage the electrical ignition switch.
OPERATION
Vehicles equipped with an automatic trans-
mission and a steering column mounted shifter:
an interlock device is located within the steering col-
umn. This interlock device is used to lock the trans-
mission shifter in the PARK position when the key
lock cylinder is in the LOCKED or ACCESSORY
position. If it is difficult to rotate the key to or from
the LOCK or ACCESSORY position, the interlock
device within the steering column may be defective.
This device is not serviceable. If repair is necessary,
the steering column assembly must be replaced.
(Refer to 19 - STEERING/COLUMN - REMOVAL).
Vehicles equipped with a manual transmis-
sion and a floor mounted shifter:on certain mod-
els, a lever is located on the steering column behind
the ignition key lock cylinder. The lever must be
manually operated to allow rotation of the ignitionkey lock cylinder to the LOCK or ACCESSORY posi-
tion. If it is difficult to rotate the key to the LOCK or
ACCESSORY position, the lever mechanism may be
defective. This mechanism is not serviceable. If
repair is necessary, the steering column assembly
must be replaced. (Refer to 19 - STEERING/COL-
UMN - REMOVAL).
On other models, the ignition key cylinder must be
depressed to allow it to be rotated into the LOCK or
ACCESSORY position. If it is difficult to rotate the
key to the LOCK or ACCESSORY position, the lock
mechanism within the steering column may be defec-
tive. This mechanism is not serviceable. If repair is
necessary, the steering column assembly must be
replaced. (Refer to 19 - STEERING/COLUMN -
REMOVAL).
DIAGNOSIS AND TESTING - IGNITION SWITCH
TEST AND REPAIR
If the key removal effort is excessive on a vehicle
with a automatic transmission first adjust the shift
linkage, (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 42RE/GEAR SHIFT CABLE -
ADJUSTMENTS).
If the ignition switch effort is excessive remove the
ignition key cylinder from the steering column. (Refer
to 19 - STEERING/COLUMN/LOCK CYLINDER
HOUSING - INSTALLATION). Check the turning
effort of the key cylinder. If the ignition key cylinder
effort is excessive replace the key cylinder. If the
ignition key cylinder operates properly look for the
following conditions.
(1) Look for rough areas or flash in the casting
and if found remove with a file (Fig. 10).
(2) Grease the lock plate actuator, lock plate, slider
and locking link.
Fig. 9 Retaining Pin
1 - IGNITION SWITCH
2 - KEY/KEY CYLINDER (RUN POSITION)
3 - RETAINING PIN
Fig. 10 Steering Column Flash Removal
1 - FILE THIS AREA TO REMOVE FLASHING AND PROVIDE
CLEARANCE TO ELIMINATE BINDING
2 - PARK LOCK SLIDER
3 - CAUTION: NEVER REMOVE SHAFT LOCK PLATE
BR/BECOLUMN 19 - 11
LOCK CYLINDER (Continued)

REMOVAL
(1) Remove the key lock cylinder.
(2) Remove the three ignition mounting screws
(Fig. 11).
(3) Gently pull the switch away from the column.
Disconnect the electrical connector (Fig. 12).
(4) Disconnect the halo lamp wiring connector
(Fig. 12).
INSTALLATION
(1) Rotate the flag on the rear of the ignition
switch to the RUN position (Fig. 13). This step must
be done to allow the tang (Fig. 14) on the key cylin-
der to fit into the slots (Fig. 11)within the ignition
switch.
(2) With the key into the key lock cylinder, rotate
the key clockwise until the retaining pin can be
depressed (Fig. 14) or (Fig. 15).
(3) Install the key cylinder into the ignition switch
by aligning the retaining pin slot. Push the key cyl-
inder into the switch until the retaining pin engages.
After the pin engages, rotate the key to the OFF or
LOCK position.
(4) Check for proper retention of the key cylinder
by attempting to pull the cylinder from the switch.
(5) Automatic Transmission Only: Before attaching
the ignition switch to the steering column, the trans-
mission shifter must be in the PARK position. The
park lock dowel pin on the rear of the ignition switch
(Fig. 16) must also be properly indexed into the park
lock linkage (Fig. 17) before installing the switch.
(6) The flag at the rear of the ignition switch
must be properly indexed into the steering column
before installing the switch. This flag is used to oper-
ate the steering wheel lock lever in the steering col-
umn (Fig. 18). This lever allows the steering wheel
position to be locked when the key is in the LOCK
position.
(7) Place the ignition switch in the LOCK position.
The switch is in the LOCK position when the column
lock flag is parallel to the ignition switch terminals
(Fig. 16).
Fig. 11 SWITCH MOUNTING SCREWS
1 - IGNITION SWITCH
2 - SLOTS NOT ALIGNED
3 - SLOTS ALIGNED
4 - IGNITION SWITCH MOUNTING SCREWS
Fig. 12 IGNITION SWITCH AND HALO
CONNECTORS
1 - KEY-IN SWITCH & HALO LIGHT
2 - MULTI-FUNCTION SWITCH
3 - TURN SIGNAL SWITCH & LEVER
4 - IGNITION SWITCH
5 - SPEED CONTROL
Fig. 13 FLAG IN RUN POSITION
1 - REAR OF IGNITION SWITCH
2 - PARK LOCK DOWEL PIN (RUN POSITION)
3 - FLAG (RUN POSITION)
19 - 12 COLUMNBR/BE
IGNITION SWITCH (Continued)